It’s a Journey, not a Destination
Digital Transformation isn’t a single initiative; it’s a journey that requires a structured, strategic approach. At LSI, we guide manufacturers through eight critical stages that build upon one another to create a scalable, sustainable digital foundation. From laying the groundwork with automation and connectivity, to unlocking enterprise-wide insight and continuous optimization, each phase is designed to deliver real, measurable value while preparing your organization for what’s next.
Stages of Transformation
Explore each stage: Control, Connect, Collect, Model, Store, Visualize, Analyze, and Optimize to see how we help you move from fragmented data to fully integrated, data-driven operations.
Stage one
Control
Description
This foundational stage involves establishing robust, standardized automation and control systems including PLCs, DCSs, HMIs, and SCADA systems that govern equipment behavior and process execution. By modernizing control layers, you ensure repeatable, predictable operations and create the first layer of digital readiness. It’s where reliability and consistency begin.
Challenge
Many manufacturers still operate with legacy PLCs, DCSs, siloed HMIs, or outdated SCADA systems, which often lack visibility, scalability, or consistent logic across equipment and lines. These gaps can cause frequent downtime, delays in troubleshooting, and inhibit the ability for integration with higher-level digital systems.
Benefit
Upgrading and standardizing control infrastructure improves system uptime, eases diagnostics, and lays the groundwork for digital integration. It enables faster troubleshooting, smoother expansion, and opens the door for real-time data collection and optimization efforts.
Stage two
Connect
Description
Connectivity transforms isolated machines into networked assets that can communicate with each other and with enterprise systems. This stage implements industrial networking, secure OT/IT convergence, and standardized communication protocols (like OPC UA, MQTT, EtherNet/IP), creating a seamless digital thread across the plant floor.
Challenge
Legacy equipment often lacks connectivity, and even newer systems can be difficult to integrate due to protocol mismatches or network security concerns. Without a scalable and secure communication layer, data remains trapped, and cross-system coordination becomes nearly impossible.
Benefit
A connected plant enables real-time monitoring, remote access, and seamless integration with MES, ERP, and cloud platforms. It reduces manual data entry, improves responsiveness to events, and serves as the foundation for smart factory initiatives.
Stage three
Collect
Description
Data collection focuses on capturing operational, quality, maintenance, and environmental data, not just continuously, but accurately and in context. It involves deploying sensors, configuring tags, defining frequencies, and ensuring timestamp and unit consistency so that downstream systems receive trustworthy, actionable inputs.
Challenge
Manufacturers often collect either too little or too much data, or worse, collect the wrong data entirely. Inconsistent naming conventions, lack of structure, and missing context can render even the most sophisticated analytics tools useless.
Benefit
When data is collected intentionally and with context, it becomes a powerful resource. High-integrity data supports real-time decision-making, historical analysis, and predictive modeling, ensuring the right people have the right information at the right time.
Stage four
Model
Description
Modeling organizes your data collected into a logical structure, often based on physical equipment, process flow, or organizational hierarchy. This might take the form of a Unified Namespace (UNS), ISA-95-based asset model, or a semantic tagging architecture that enables scalable integration and reusable logic.
Challenge
Without a unified data model, organizations suffer from inconsistent tags, redundant logic, and incompatible reporting. This inconsistency creates technical debt, increases maintenance effort, and hinders the ability to scale across lines or plants.
Benefit
A robust data model ensures that every system speaks the same language. It enables faster system integration, simplifies reporting, accelerates deployment of analytics and dashboards, and improves the maintainability of digital infrastructure over time.
Stage five
Store
Description
Storing data properly involves more than just logging it. It’s about defining what should be stored, for how long, and where; whether in local historians, enterprise databases, or scalable cloud platforms. This stage ensures data is accessible, secure, and retention-aligned with regulatory, operational, and business intelligence needs.
Challenge
Improper storage, whether it’s missing timestamps, poor query-ability, or over reliance on spreadsheets makes data difficult to access and impossible to trust. Without data governance and a storage strategy, scalability, traceability, and audit readiness suffer.
Benefit
With the right architecture in place, data becomes an invaluable enterprise asset. Teams can access historical trends, power dashboards, support root cause analysis, and feed AI/ML tools. Storage strategy becomes the anchor of long-term digital growth.
Stage six
Visualize
Description
Visualization turns raw data into intuitive insights through dashboards, HMI/SCADA screens, and role-specific interfaces. Whether on the plant floor or in the boardroom, visual tools help operators, engineers, and executives understand what’s happening and why it’s happening, in real time.
Challenge
Without thoughtful visualization, data overload, inconsistent displays, or confusing KPIs can lead to decision fatigue or poor engagement. Static dashboards and non-contextual alerts often result in underutilized systems and limited trust in the data.
Benefit
Effective visualization brings clarity and engagement to complex systems. It empowers users to spot trends, respond faster to issues, and make informed decisions that drive productivity and quality. Tailored visualizations increase system adoption and operational transparency.
Stage seven
Analyze
Description
The analysis stage introduces structured problem-solving using data. From simple trend comparisons to advanced root cause analysis, this phase uses statistical tools, BI platforms, and domain knowledge to identify bottlenecks, inefficiencies, and patterns that were previously invisible.
Challenge
Many organizations struggle to move beyond basic reporting. Without analytical frameworks, historical context, or a data-literate workforce, it’s hard to translate raw data into actionable improvements.
Benefit
Structured analysis enables proactive problem-solving. It helps prioritize improvement opportunities, validate operational theories, and identify causes of waste, downtime, or variability; forming a bridge between predictive and prescriptive strategies.
Stage eight
Optimize
Description
Optimization is the culmination of the digital journey, where insights drive action, and improvements become continuous. This stage leverages AI/ML, feedback loops, automation, and performance benchmarks to maximize throughput, efficiency, and quality in a sustainable and scalable way.
Challenge
Without integrated systems and agile processes, most organizations struggle to adapt and improve consistently. Optimization efforts often stall due to lack of visibility, data trust, or organizational alignment.
Benefit
Optimization delivers sustained competitive advantage. By using your data to continuously improve processes, automate decisions, and guide investment, you unlock higher yields, lower costs, and a resilient, future-ready operation.
Ready to Transform Your Operations?
Take the first step towards Digital Transformation with LSI by your side. Our team of experts is eager to craft tailored solutions that drive operational performance improvement. Whether you are just getting started with your digital foundation, or looking to unlock advanced insights leveraging the latest technologies, our team of consultants, developers, and engineers are ready to guide you to success.